FORNEY CORPORATION

Forney Corporation3405 Wiley Post RoadCarrollton, TX 75006Phone: 972-458-6100Fax: 972-458-6650www.forneycorp.comSales offices: Belgium, China, Germany, Japan, Poland, Singapore, United Kingdom

Q87 OIL GUN

372000-66

REV A

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PROPRIETARY NOTICE

The contents of this publication are proprietary data of Forney Corporation. Reproduction oruse of any part of the publication for purposes other than the support of the equipment for whichit is published is permissible only if expressly authorized in writing by Forney.

The original source of this publication is Forney Corporation. Forney Corporation can notaccept responsibility for the accuracy of any modifications made to this document subsequent toits issuance, except in the case where such modifications were made with the express writtenapproval of Forney Corporation. All subsequent users of this publication should contact ForneyCorporation to confirm the original contents of this publication.

Additional copies of this publication may be purchased from Forney. When ordering orrequesting cost information, refer to the publication number appearing on the title page. Addressto the attention of the Sales Department, Forney Corporation, 3405 Wiley Post Road,Carrollton, Texas 75006-5185.

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INTRODUCTION

This manual contains information for the Forney Q87 Igniter that was designed andmanufactured by Forney Corporation, 3405 Wiley Post Road, Carrollton, Texas.

All personnel should become thoroughly familiar with the contents of this manual beforeattempting to operate or maintain the system. Because it is virtually impossible to cover everysituation that might occur during operation and maintenance of the equipment described in thispublication, personnel are expected to use good engineering judgement when confronted withsituations that are not specifically mentioned herein.

The user should update this manual whenever significant changes are made to the system. To beof value, the manual must always reflect the latest configuration of the equipment. It should benoted, however, that Forney Corporation will furnish updated pages only if a modification isauthorized by Forney and accomplished under Forney supervision.

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TABLE OF CONTENTS

SECTION TITLE PAGE

LIST OF FIGURES

1 Oil Gun Assembly..........................................................................................22 Exploded View of Oil Atomizer Assembly......................................................63 Exploded View of A Mechanical Atomizer .....................................................7

LIST OF TABLES

1 List of Recommended Spares.......................................................................14

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372000-66 Rev AQ87 OIL / GAS IGNITER

1.1 DESCRIPTION

The Forney Q87 Igniter (Figure 1) is a versatile and reliable source of ignition energy and support forcoal, oil, or gas burners. The Q87 Igniter features repeatable fuel ignition and stable flame front. TheQ87 Igniter is NFPA-rated as a Class 1, 2, or 3 Igniter, depending on the application: Class 1(Continuous Igniter) is used for light-up and support under all conditions; Class 2 (Intermittent Igniter) isused for light-up and support under prescribed light off conditions; and class 3 (Interrupted Igniter) isnot intended for warmup or support. A heat input range from 8.0 to 30.0 MBtu/hr makes the Q87Igniter well suited for boiler warmup or main flame ignition and stabilization.

The Q87 Igniter is provided with a durable High Energy Spark Igniter (HESI) for repeatable lightoff. Refer to the HESI Service Manual (publication No. 38407702) for detailed HESI information.

The major components of the Q87 Igniter are a mounting tube, guide tube assembly, fuel gun, andHESI. A factory-mounted junction box is standard, with all onboard electrical devices wired to theterminals. Figure 1 shows a typical oil-fired Q87 assembly.

1.1.1 Mounting Tube

The mounting tube is welded to the burner front plate, in most cases, and provides support for theigniter assembly. The igniter guide tube slides into the mounting tube and is secured in place by a splitclamping ring (squeeze collar), which is bolted to the mounting tube. The squeeze collar also acts as apacking gland follower. The packing gland prevents windbox pressure from leaking between themounting tube and guide tube.

1.1.2 Guide Tube Assembly

The guide tube assembly contains the working parts of the igniter and houses the oil fuel gun and HESIspark rod. The guide tube outside diameter is 4 inches. A 3.6-inch diameter diffuser cone is located atthe tip to provide a stable flame (Figure 2). The guide tube transports cooling air from a low pressure (6in. w.c.) air supply system to the igniter tip where it enters the furnace keeping the diffuser cool andsweeping foreign material away from the tip.

1.1.3 Fuel Gun

The Q87 igniter uses a fuel oil gun equipped with a mechanical atomizer tip. Because of the quick-disconnect coupling, the fuel gun can be removed easily to perform maintenance on the gun.

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Fig

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1.

Q87

Ign

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Ass

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Figure 2. Oil Gun, Diffuser, and HESI Spark Tip Settings

Separate limit switches are provided to generate gun coupled and gun extended status signals for theburner management system (BMS). During the lightoff sequence for the igniter, the BMS verifies thatthe oil gun is coupled and then causes a pneumatic cylinder to extended the gun to its firing position. When the gun is in position, the BMS extends and energizes the HESI and opens the igniter fuel valve. If igniter lightoff is successful, the BMS permits the oil gun to remain in its firing position until it isremoved from service. Extension and retraction of the oil gun is controlled by a pneumatic cylinder. The retraction assembly includes a limit switch whose contacts close when the oil gun is in its firingposition. When the igniter is not in service, the retraction assembly pulls the oil gun back inside themount tube to protect the atomizer tip from heat and debris in the boiler.

1.1.4 High Energy Spark Igniter

The HESI spark rod provides a 12-joule spark that ignites the fuel/air mixture. The HESI consists of afouling-resistant, surface-gap spark tip connected to a positioning rod, power unit, and cable. When theHESI is not required for igniter lightoff or oil gun purge, a separate HESI retraction cylinder holds thespark tip inside the mount tube. See the HESI Service Manual for details.

1.1.5 Flame Detector

The Forney Q87 Igniter requires proof of ignition from an outside mount detector. For moreinformation on the Forney flame detectors, please refer to the appropriate flame detector servicemanual.

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2.1 SPECIFICATIONS

Dimensions (inches):Guide Tube OD: 4Length: as requiredMount Tube OD: 4.5Length: as required

BTU Rating (nominal) 8 to 30 MBtu/hr

Fuel Type: No. 2 oil

Fuel Supply Pressure: 200 psig at igniter inlet

Oil Atomizer Type: Mechanical

Cooling Air Requirements (scfm): 80@ 6 in. w. c.

Opacity during Cold Light-Off: <10% at 8 to 12 Mbtu<20% at 25 to 30 Mbtu

Ignition Method: High Energy Spark Igniter

Ignition Unit Specification: See HESI Series 90 publication, 38407702

Material of Construction: Guide tube and mounting tube – carbon steelDiffuser cone - 309 stainless steel;4.00-inch tip portion of guide tube 304 stainless steel,

Retraction Cylinder Operating Air Pressure 60 to 100 psig

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3.1 SAFETY

Safety is the responsibility of each individual who installs, operates, or maintains Forney equipment. Forney includes personnel safety as a basic design element of the Q87 Igniter.

Observe the following safety instructions prior to performing installation, operation, or mainten-anceinstructions:

WARNING

Hazardous voltage is present and seriousinjury to personnel can occur. See HESIService Manual.

1. Use this equipment only for its intended purpose.

2. Follow only the installation, operation, and maintenance procedures discussed in this publication andon appropriate drawings.

3. Ensure that all electrical apparatus used to perform work on this equipment is in good workingorder and has been calibrated correctly.

4. Do not lift or disconnect grounding cables/wires while equipment is energized.

5. Do not perform modifications on this equipment.

6. The HESI power unit enclosure and the igniter guide tube should be grounded. See HESI ServiceManual for details.

7. Before opening the HESI power unit’s hinged cover, disconnect the electrical supply from the box. Allow at least 2 minutes for the capacitor to discharge. Exercise extreme care when the power unitcover is open. Refer to the HESI Service Manual for complete safety constructions for the HESIequipment.

8. Ensure that no voltage is present prior to disconnecting terminations.

9. Adhere to safety-related information on all drawings.

10. Close the manual fuel shutoff valves before performing maintenance or troubleshooting procedures.

11. When removing the igniter assembly from an operating furnace, wear protective clothing andinsulated gloves. While observing the igniter flame through an open observations port, wear a faceshield and protective clothing.

12. Collect in drip pans all spilled oil caused by oil gun removal or other sources. Clean up or removespilled oil from the burner front.

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13. Replace the coupling assembly copper gaskets after each oil gun disassembly.

14. If the igniter is equipped with automatic retraction devices, maintain at least a 12-inch distancebehind the oil gun to avoid injury from sudden oil gun retraction.

Only knowledgeable and qualified technicians should be allowed access to this system or to itscomponents. The installation, maintenance, and operation of electronic equipment entail severalelements of danger. Carelessness can result in serious injury or death from electrical shock, falls, orimproper use of tools and test equipment.

4.1 INSTALLATION

A detailed description of the Q87 Igniter installation follows. To obtain job-specific installationinstructions, request the appropriate arrangement and installation drawings from Forney Corporation. During installation, protect terminal boxes, spark rods, surfaces, round tubes, or any protruding devicesfrom accidental bumps or bending forces.

Installation of the Q87 Igniter assembly includes five major tasks: affixing the mounting tube to theburner front plate, inserting and positioning the guide tube assembly, installing fuel piping, installingcooling/combustion air piping, and connecting all wiring.

4.1.1 Mounting Tube

The mounting tube is affixed permanently to the burner front plate and supports the igniter assembly. Many retrofit installations may have an existing mounting tube that can be reused. To reuse an existingmounting tube, adequate sliding clearance must exist between the inside diameter of the mounting tubeand the outside diameter of the guide tube. If a suitable mounting tube is not available, one must beinstalled. In cases where a mounting tube must be installed, perform the following steps:

1. Cut a hole in the front plate in the location desired or as indicated on the installation drawing. Thediameter of the hole should be slightly larger than the outside diameter of the mounting tube.

NOTE

Occasionally, air vanes or other parts ofthe burner have to be trimmed in order toprovide clearance for the mounting tubeand igniter guide tube.

2. Insert the mounting tube through the front plate and into the burner area. Position the mounting tubeto the correct distance and angle shown on the installation drawing.

3. Seal-weld the mounting tube to the burner front plate using a full penetration weld. (For carbonsteel, a 6011 weld rod may be used). On some older installations where cast iron plates must bepenetrated, a steel flange or cover plate can be bolted to the cast iron, so that the mounting tube canbe welded to that flange or plate.

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4.1.2 Guide Tube Assembly

The following procedure describes the installation steps necessary for the correct positioning of theguide tube assembly.

1. Inspect the diffuser area for damage, cleanliness, and proper HESI spark rod position. The HESIspark rod is factory set and should not need adjustment. If necessary, refer to Figure 2 for HESIspark rod tip settings.

2. Loosen the packing and clamping nuts on the mounting tube.

3. Apply a thin coat of high-temperature lubricant to the outside surface of the guide tube, and slide theguide tube through the squeeze collar. Avoid contact with internal burner parts, such as air vanes orburner sleeves. Guiding the igniter into place from inside the windbox may assist in this procedure.

4. Position the guide tube assembly to the depth shown on the burner installation drawing. Forreplacement applications, insert the furnace end of the guide tube assembly to the same location asthe previous igniter. The critical dimension is the Q87 Igniter tip relative to the burner throat or thewaterwall surface. As a general rule, when in the extended position, locate the Q87 Igniter tip 3inches behind the burner tip vertical plane or, in the case of wall firing, 2 inches back from the centerline of the waterwall tube surface.

4.1.3 Tack-Welding of Components

Four devices on the assembly are locked in position by setscrew fasteners. These fasteners are usedfor shop assembly and can assist in field adjustment. Tack-welding of these components is done at thefactory. However, each of the following points should be field-checked for these welds.• Coupling assembly mounting ring

• Retractor barrel clamp

• Fuel gun coupled limit switch clamp

• Retract/extend limit switch strikers

Do not tack-weld the HESI retractor rod clamp. Correct any missing or damage welds before startup.

4.1.4 Fuel Piping

If fuel piping is part of Forney’s supply, Forney provides a site-specific drawing to assist with pipinginstallation. Forney recommends using the following general guidelines when installing the piping:• To prevent the transportation of foreign particles to the fuel tip during commissioning, ensure that all

fuel piping and flexible hoses have been blown free of debris and moisture.

• Tapping off a fuel header from the top or side reduces the possibility of contamination duringoperation.

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• Ensure that oil line accumulators, if supplied, are in place, and accumulators are pressurized withnitrogen set to 60% of design igniter operating oil pressure.

• Install strainers with the strainer elements oriented in the correct directions.

• Install flexible hoses to accommodate retraction/extension of fuel guns and boiler vertical expansion.

• Install the flexible hoses with all of the bends in one plane. The hoses cannot withstand twisting orkinking; if necessary, install an additional union.

4.1.5 Cooling/Combustion Air

1. To prevent contamination of the igniter during commissioning, ensure that all cooling/combustion airpiping is blown free of debris and moisture.

2. Before tightening the mounting tube clamping ring, it may be necessary to rotate the guide tube toorient the air connection to the desired position (90 increments) so that the guide tube easily acceptsthe cooling/combustion air flexible hose. In order to maintain proper orientation of the oil gun andHESI, remove the four bolts on the rear flange of the guide tube. While maintaining the HESI andoil gun in the same location, rotate the guide tube until the cooling/combustion air connection acceptsthe flexible air hose, and reconnect the four bolts.

3. Connect the flexible air hose to the cooling/combustion air inlet on the guide tube. Install the flexibleair hoses so as to allow for maximum boiler expansion. Install the flexible air hoses with all bends inone plane; the hoses cannot withstand twisting or kinking. If necessary, install an additional union.

4.2 Wiring

Consult the control system wiring diagram for site-specific wiring connections. The standard Q87 Igniteris furnished with a factory-mounted-and-wired junction box, in which all control wire connections aremade to terminal strips (Figure 3).

A typical I/O list for the Q87 Igniters includes the following:

4.2.1 Control Outputs

• HESI power unit

• HESI extend solenoid

• Unit extend/retract solenoid

• Fuel valve open/close solenoid

• Purge valve open/close solenoid.

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Figure 3. Local Igniter Wiring

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4.2.2 Control Inputs

• Fuel gun coupled limit switch

• HESI extend limit switch

• Unit extend/retract limit switches

• Fuel valve open/close limit switches.

Before commissioning the equipment, test all electrical components for proper operation by energizingthe component while it is isolated from the system.

4.3 Flame Detector for Q87 Igniter

Flame detection of the Q87 Igniter is through an externally mounted detector. Consult the appropriateflame detector drawing and service manual for installation details.

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5.1 COMMISSIONING

Before commissioning the Q87 Igniter, complete all of the steps listed in the Installation section of thisservice manual. Use the following checklist to ensure that the Q87 Igniter is ready for initial operation.

• The fuel and air piping configuration is correct, and dampers, valves, strainers, and instrumentationare installed properly.

• The cooling/combustion air connections to the guide tube are installed according to the precedinginstructions or the installation drawings (if provided).

• All retract cylinder piston rods are clean and free of paint or debris; retract cylinder exhaust ventsare clean undamaged.

• The fuel oil accumulator is precharged properly. Refer to the installation section.

• All electrical components are wired properly and tested, including the HESI power unit and sparkrod assembly.

• Fuel oil lines are connected properly at the header and at the fuel gun.

• Valves and strainers are installed oriented correctly.

To commission the Q87 Igniter, complete the above checklist, and then perform the following steps.

1. Remove the fuel gun from the igniter assembly to clean and inspect the oil gun tip.

a. Refer to the Oil Gun Removal subsection within the Maintenance section for disassemblyprocedures.

b. Remove any rust or scale that formed in the tubes and tip during storage. Do not clean orificeswith steel wires or other steel tools.

c. Remove the lubricant coating (applied before shipping) from the tip.

d. Reassemble the fuel gun using the same precautions as noted in the disassembly instructions. Refer to the Maintenance section for assembly instructions.

e. Install new copper ring gaskets on the coupling body.

2. Replace the fuel gun into the igniter and secure in place, with the coupled limit switch made, bytightening the yoke against the head of the gun.

3. Place the cooling/combustion air system into service by starting the cooling/combustion air fan(s)and opening the manual isolation valves.

4. Adjust the manual isolation valve to set the cooling/combustion air pressure to approxi-mately 6

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inches w. c. above furnace pressure, as measured at the ½-inch connection.

5. Prepare to place the Q87 Igniter into service by completing the following steps:

NOTE

Before proceeding, all light-off permissivesmust be met.

a. Start oil pumps.

b. Open the manual oil valve at each igniter.

c. Set the igniter oil header pressure regulator to obtain the required supply pressure at the igniterinlet.

8. Initiate a START command to the Q87gniter while observing the fuel pressure.

9. If the Q87 Igniter fails to ignite, refer to the Troubleshooting section.

10. When the igniter is in service, the ignition point should be just off the tip of the oil gun. A properlyburning oil flame is bright yellow at its base and more orange as the flame travels into the furnace. The very tip of the flame has a small amount of dark tails, but as the furnace warms up, the dark tailsdiminish. If these conditions exist, no adjustments are necessary. If the flame is not burningaccording to these descriptions, refer to the Troubleshooting section.

11. Initiate a shutdown command to the igniter. Ensure that the fuel valve fully closes. The gun shouldgo through a purge cycle before it is retracted.

12. Repeat the start and shutdown procedures in steps 7 and 10 to demonstrate light-off repeatability.

13. Ensure that the oil gun purge sequence duration is long enough to remove all of the oil from the gun. A duration of 2 minutes is recommended.

14. After the Q87 Igniter has been commissioned and adjustments have been optimized, practicenormal maintenance procedures, as outlined in the Maintenance section.

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6.1 OPERATION

The Q87 Igniter is ready for normal operation after the installation and commissioning procedures havebeen completed.

Place the Q87 Igniter into service from a cold state as follows:

1. Prepare the boiler for lightoff by satisfying all lightoff permissives.

2. Pressurize the igniter oil distribution header by performing the following instructions:

a. Start the oil pumps.

b. Open the header trip valve.

3. Start the cooling/combustion air fan(s) or open an air path from other air sources. The fans mustremain in service while the boiler is in operation, unless an alternate means of cooling the igniter tip isprovided.

4. Initiate an igniter START command. The following sequence of events occurs as the Q87 Ignitergoes into service (the following information is typical; individual systems may vary):

a. An ignition time trial begins (usually 15 seconds).

b. The oil gun will move to the extended position if not already there.

c. The HESI power pack is energized, and the HESI spark rod begins sparking.

d. The igniter oil valve opens to admit fuel to the oil gun.

e. Ignition occurs within a few seconds of the fuel admission.

f. The flame detector detects the flame when ignition occurs.

If an igniter flame is not detected within the ignition time trial limit, an igniter trip is initiated, the fuel valveis closed, and the HESI is deenergized. The gun is purged prior to being retracted, unless a fuel safetytrip or other safety condition prevents the purge cycle from running.

NOTE

On a manually controlled igniter system, use thetime limits and event sequence discussedpreviously for guidance.

If the igniter flame is detected, the igniter remains in service until the operator initiates shutdown, or the

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burner management system trips the igniter out of service.

As the boiler starts to warm up, additional igniters can be placed in service. Heat input should belimited to the boiler manufacturer’s recommended start-up rate.

To remove the Q87 Igniter from service, either manually or automatically, under normal boiler operatingconditions, follow these steps (the following information is typical; individual systems may vary):

1. Initiate an igniter STOP command. The following oil gun purge sequence occurs:

a. The HESI power unit is energized and starts to spark.

b. The oil block valve closes.

c. The purge valve opens for 60 to 120 seconds to admit purge air to the oil gun.

d. After 60 seconds, the HESI is deenergized.

e. After the purge period of 60 to 120 seconds, the purge valve closes.

f. The oil gun retracts.

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7.1 TROUBLESHOOTING

If the igniter fails to ignite, several conditions may be at fault.

NOTE

Frequently, initial lightoff requires several attempts to ensure that the fuel pipingsystem is purged of air and full of fuel.

Also, ensure that the atomizing piping is free of water.

1. If the igniter does not ignite, ensure that the following conditions exist:

• All manual valves in the fuel supply line to the igniter are open.

• All control, trip, and block valves in the oil lines are functioning properly. Ensure that the blockvalves open smoothly and are fully open within 2 to 5 seconds after the START command.

• Fuel pressure is regulated to within ±5 psi of its setpoint value during lightoff. Any pressuredeviation should be recovered to the setpoint within 3 to 5 seconds.

• The HESI cable is connected properly, and voltage is present at Terminals 1 and 2 in the HESIpower unit.

• Ensure that the HESI spark tip is firing. If the spark rod cannot be observed in place, mark therod so that it can be repositioned to its previous location. Remove the spark rod from the guidetube, and place the rod in a safe location away from any personal contact. Observe the rod andthe power unit’s lens for visible emission of three sparks per second. If the spark rod assemblyfunctions properly, reinsert the rod into the guide tube at the rod’s original position, which wasmarked previously. If the HESI spark rod does not function properly, refer to the HESIService Manual (Manual No. 38407702).

• The HESI spark rod tip is positioned correctly, as shown previously in Figure 2, and is sparkingduring the ignition process.

• When fuel is available to the oil gun, and a spark is present but no oil spray is observed, or anerratic spray exists, remove the oil gun, and inspect the gun for tip fouling. Disassemble andclean or repair the gun, as required. Refer to the Maintenance section, Oil Gun Removal andOil Gun Assembly subsections.

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NOTE

Tip fouling and tip carbonization may occur, due to an inadequate purge or a leakingshutoff valve. This condition can result in oil migrating to the hot tip. It may be necessaryto increase the purge time or check for shutoff valve leakage. Check for this leakage byremoving the igniter end of the flexible oil hose and allowing the oil to collect in acontainer. While oil pressure is available to the shutoff valve, observe the flexible oil hosefor oil leaks. If leakage is evident, repair the shutoff valve. Fouling, failure to light, anderratic combustion also can be caused by contaminate or degraded oil. Oil stored forlong periods of time can form paraffins and other solids that can plug orifices.

2. For an installation where remote or local automatic light-off sequencing and flame detection isinvolved, consult system operating logic and ensure that the following conditions exist:

• The oil gun coupled limit switch contact is actuated, and the limit switch is closed; this prohibitsany light-off sequence.

• The unit retract limit switch contacts are actuated in either the retracted or extended position.

• The speed control valves are adjusted to extend or retract the 6-inch stroke in 2 to 3 seconds.

• The igniter time trial for ignition is adequate to allow the oil to reach the burner tip and stabilize.

3. If the igniter lights, but the flame fails to remain lit on, ensure that the following conditions exist:

• Oil pressure is maintained at the required level throughout the lightoff trial interval.

• Cooling/combustion airflow is at the required level, and it remains stable as the igniter starts.

• Burner airflow is not blowing out the flame.

• The flame detector is functioning properly.

• The flame detector is sighted properly.

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4. If the igniter lights but an inadequate flame exists, (i.e., orange flame with dark tails, or the ignitionpoint of the oil flame is more than 2 to 3 inches in front of the tip of the oil gun) ensure that thefollowing conditions exist:

• The amount of combustion airflow directed behind the oil gun is adequate. Dark tails usuallyindicate insufficient mixing of the fuel with the combustion air.

• The oil gun atomizing tip is clean and free of any obstruction.

8.1 MAINTENANCE

The Q87 Igniter components discussed below require periodic maintenance to ensure long and reliableservice. On a periodic basis, complete preventive maintenance activities.

Use the following list as a guideline for the tools required to perform preventive maintenance:

TOOL: 9/16- socket wrenchUSED ON: packing gland, mounting tube, guide tube rear flange; 3/8-inch nut

TOOL: large adjustable wrenchUSED ON: fuel/atomizing union

TOOL: open-end wrenchUSED ON: atomizing tip

TOOL: large adjustable pipe wrenchUSED ON: gas lines, primary gas supply union

TOOL: Allen wrenchesUSED ON: HESI spark rod retract limit switches

TOOL: screw driversUSED ON: HESI junction box and gas orifices

TOOL: 1/16-inch soft copper wireUSED ON: gas orifice (for cleaning)

CAUTION

Use protective clothing and gloves iffurnace is in operation.

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8.1.1 Oil Gun

Remove the oil gun for maintenance every 3 months or after 100 hours of operation, whichever comesfirst. Remove the oil gun, clean the tip, and reassemble the gun, as follows:

8.1.1.1 Oil Gun Removal

1. Close the manual isolation valves in the oil line that connects to the gun assembly. Tag the valve Outof Service.

2. Loosen the yoke bolt and move the yoke downward. As the connection is opened, take care anypressure is relieved and the isolation valves are holding tightly.

CAUTION

Do not place the hot tip of the oil gunassembly in solvent or drip pans thatcontain oil. Flash fires could result.

3. Slowly pull the handle on the oil gun, and carefully slide the oil gun assembly from the guide tube.

4. Set aside the oil gun, and allow it to cool slowly.

5. Inspect the oil port at the coupling assembly and ensure that the manual isolation valve is not leaking.

6. When the tip is cool, place the oil gun into a maintenance fixture. Use a smooth-sided wrench tounscrew the atomizing tip from the oil gun.

CAUTION

All oil passages must be free of foreignmaterial that could alter the spray patternof the oil.

7. After the tip has been removed, cover and protect the threads of the oil gun.

8. Clean the atomizing tip with a commercially approved hydrocarbon solvent and a soft copper wireto remove all deposits.

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8.1.1.2 Oil Gun Reassembly

1. Apply a high-temperature-resistant lubricant to the threads of the atomizing tip. Install the atomizingtip on the end of the oil tube.

CAUTION

Do not apply excessive torque on theatomizing tip. Binding or galling of the tipcan occur if disassembly is attempted whileit is hot from service. Use of a pipe wrenchor serrated jaw wrench could damage theatomizing tip and eventually cause it to fail.

2. Use an open-end wrench to tighten the atomizing tip to 60 ft-lb torque.

3. Remove and replace the two copper gaskets at the quick-disconnect coupling. Never reuse thecopper gaskets.

4. Slide the oil gun assembly into the guide tube until the oil port is sealed against the couplingassembly.

5. Move the yoke upward, over the oil gun head and tighten the yoke screw to 30 ft-lb torque. Ifmore torque is required to seal the quick-disconnect coupling, check the gasket seal surfaces forproper installation. Moving the yoke into position actuates the oil gun coupled limit switch.

6. Open the manual isolation valves in the oil line that connect to the gun assembly. Remove the Out ofService tags.

7. When the gun is placed in service, ensure that no leaks are present around the quick-disconnectcoupling gaskets and hose connections. Correct any leaky joints.

8. Remove and clean the oil line strainer after 50 hours of oil gun operation.

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8.1.2. Retract Assembly

Every 6 months ensure that the following conditions for preventive maintenance of the retract assemblyexist:

• Compressed air pressure is maintained between 60 to 100 psig.

• Compressed air is moisture free, and the internals of the retract cylinder are dry.

• Piston rod surface is free of corrosion, deposits, or wear.

• The unit extends and retracts without jerking, binding, or slamming in either direction.

• Extend/retract limit switches are actuated at full stroke.

• Exhaust flow controls (speed control needle valves) are adjusted properly (2 to 3 seconds to extendor retract 6-inch stroke).

8.1.3 Retract Cylinder Adjustment

Use the following steps to adjust the retract cylinder speed control:

1. Unlock the exhaust flow control screw by turning the locking nut approximately one-half turn to theright.1

2. Turn the exhaust flow control screw to the right and to its end-stop point before operating theretract/extend cylinder. This recommended start-up procedure will keep the cylinder stroke undercontrol.

3. Operate the air control valve, and then adjust the exhaust flow speed by adjusting the exhaust flowcontrol screw to the left.

4. While holding the screw, lock the exhaust flow control screw setting by turning the locking nut to theleft.

8.1.4 Flame Detector

Clean the ignition flame detector lens every 6 months or more often under extreme conditions. Refer tothe flame detector’s service manual for details.

8.1.5 High Energy Spark Igniter

Remove and inspect the spark rod assembly every 6 months or during planned boiler outage. Refer tothe HESI Service Manual for details.

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8.1.6 Air Tube and Diffuser

Every 12 months or planned boiler outage, inspect the air tube and diffuser cone from the furnace side.Remove the flex hose at the igniter and inspect for obstruction. Clean or blow out as necessary. Onnaturally aspirated models, the air entrance is located at the rear of the guide tubes. The entrance mayplug during operation from fly ash or other objects and should be checked and cleaned out periodicallyto avoid problems from low cooling airflow.

8.1.7 Combustion Air Fan and Motor Set

Every 6 months, or more often under adverse conditions, clean or replace the air filters. If required,lubricate bearings and stroke control dampers/isolation valves, if provided.

9.1 STORAGE

Store the Q87 Igniter in a clean, dry atmosphere. When possible, store the assembly in its originalshipping container until used. If the Q87 Igniter is removed from its shipping container, store it in ahorizontal position supported at both ends of the guide tube. Protect both guide tube ends from damagedue to inadvertent bumps or blows. Cover the Q87 Igniter with plastic to keep it free of dust and dirt. Storage longer than 30 days requires humidity less than 85% and temperature less than 120° F.

Forney Corporation

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10.1 RETURN OR REPAIR SERVICE

Forney Corporation warrants this product to be free of defective material and workmanship. Forneywill repair or replace this equipment if it is found to be defective upon receipt, but not later than 90 daysfrom the date of shipment.

Prior to returning any material to Forney, obtain a Return Material Authorization (RMA) from Forney. Clearly mark the RMA number on all shipping containers and accompanying documents. Forneyaccepts only materials submitted in accordance with the RMA instructions.

Use any of the following methods to obtain an RMA:

1. Phone: (972) 458-6100 or 458-6142

2. 1-800-356-7740 (24-hour direct line)

3. Fax: (972) 458-66009.1 STORAGE

Provide Forney with the following information:

• List of equipment to be returned by stock number/model number.

• Reason for return

• Company name and address of customer.

• Customer’s requested mode for return shipping.

• Customer’s purchase order number for repairs (if applicable).

• Customer’s requested return date.

• Name and address to which Forney is to return-ship and any special container marking informationthat may be required.

• Name of individual (customer’s representative) requesting the RMA.

After receiving the RMA, clearly mark the RMA number on all shipping containers and accom-panyingdocuments.

Forney Corporation is not responsible for materials returned without proper authorization andidentification.

Forney Corporation

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Return the material to:

Attn: Return Material]Forney Corporation3504 Wiley Post RoadCarrollton, Texas 75006-5185

Exercise care when packing the materials to be returned. The shipper will be advised of any damagedue to improper packing and will take no further action in connection with this material return until theshipper provides clearance for further disposition.

11.1 SPARE PARTS

When ordering spare parts, furnish the following information to:

Attn: Renewal PartsForney Corporation3405 Wiley Post RoadCarrollton, Texas 75006-5185

1. Contract number.

2. Customer purchase order number.

3. For each part ordered, provide the following information:

a. Part name.b. Part number.c. Part description.d. Quantity required.

Forney Corporation

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11.1.2 Recommended Spare Parts

The recommended spare parts list in Table 1 advises of the minimum stock level of replacement partsthat should be in the customer’s stock for system start-up and the first year of operation. Replacementparts should be ordered as necessary to maintain the suggested stock of spare parts at therecommended level.

Table 1. Q87 Igniter Minimum Recommended Spare Parts

Part Description Qty

Oil Gun Copper Coupling Gaskets 100 for every 5 igniters

HESI spark tip and cable 1 for every 5 igniters

HESI Power Unit 1 for every 10 igniters

Limit switch for oil gun advance/retract assembly 1 for every 5 igniters

Atomizer tip 1 tip for every 5 igniters

Forney Corporation

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Q87 Oil/Gas IgniterCOMMISSIONING

CHECKLIST

After reading this service manual and following its instruction, complete the Commissioning Checklistwhile following the guidelines discussed in the Installation and Commissioning sections of this servicemanual. Return the completed form to Forney Corporation.

Customer name: ___________________________________________________________

Contract number: __________________________________________________________

Plant location and unit number:_________________________________________________

Number of Q87 Igniters supplied: ______________________________________________

Capacity: ________________________________________________________________

Answer “yes” or “no” to the following statements by circling the “y” or “n” response that precedeseach statement. Answer “yes” if the listed condition has been completed satisfactorily. If the answer is“no”, please explain. Use this service manual’s installation and commissioning guidelines whilecompleting this checklist.

y / n A new mounting tube was installed.

y / n The mounting tube adequately supports the igniter assembly.

y / n The igniter assembly has been checked for clearance within the burnerand does not interfere with dampers, vanes, or any other moving parts. (Explain corrections made if interferences were experienced.)

y / n Adequate igniter assembly removal distance exists.

y / n The HESI spark tip is in the correct location, per Figures 1 and 2 in thismanual. (If the tip required relocation, note the tip’s final position:______ -inch in front of the swirler.

y / n The HESI was tested independently and works properly.

y / n All fuel and air piping has been blown clean and free of debris andmoisture.

Forney Corporation

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COMMISSIONINGCHECKLIST ( Cont)

y / n The fuel gun tip has been inspected and is free of dirt and debris.

y / n All wiring and logic interlocks have been field-tested for properoperation.

y / n The Q87 Igniter has ignited on a repeatable basis, as witnessed by theowner.

OPERATING DATA:

Oil pressure to gun _________ psi

Atomizing air/steam pressureat gun (at maximum capacity) _________ psi

Gas pressure at igniter(at maximum capacity) _________ psi

Cooling/combustion air pressureat igniter ___________ in. w. c.

Windbox-to-furnace differential ___________in. w. c.

Send this form to:

Attn: Service DepartmentForney Corporation3405 Wiley Post RoadCarrollton, Texas 75006-5185